oil seal TOYOTA RAV4 2006 Service Manual PDF

U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–227
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34. INSTALL NO. 1 TRANSAXLE CASE PLUG
(a) Coat 4 new O-rings with ATF.
(b) Install the 4 O-rings to the 4 plugs.
(c) Install the 4 plugs to the transaxle rear cover.
Torque: 7.4 N*m (75 kgf*cm, 65 in.*lbf)
35. INSTALL TRANSAXLE REAR COVER SUB-
ASSEMBLY
(a) Remove any packing material and be careful not to
spill oil on the contact surfaces of the transaxle rear
cover or the transaxle case.
(b) Apply FIPG to the cover.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
NOTICE:
Make sure that the seal packing is applied in a
bead (section diameter:
1.2 mm (0.047 in.)) so
that the entire sealing surface will be evenly
sealed. The seal packing should also protrude
slightly from the flange after the installation of
the cover has been completed.
(c) Apply adhesive to the threads of bolt A.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(d) Install the cover with the 11 bolts.
Torque: 19 N*m (194 kgf*cm, 14 ft.*lbf) for bolt A
25 N*m (255 kgf*cm, 18 ft.*lbf) for other
bolts
36. INSTALL NO. 2 UNDERDRIVE CLUTCH DISC
(a) Coat the 4 discs with ATF.
(b) Install the 4 discs, 4 plates and flange to the
transaxle case.
NOTICE:
Be careful of the order of the discs, plate and
flange.
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–229
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(b) Install the 1-way clutch to the transaxle case.
NOTICE:
Make sure that the mark on the 1-way clutch
outer race is visible.
(c) Using a screwdriver, install the snap ring to the
transaxle case.
NOTICE:
The snap ring should be fully engaged in the
groove of the transaxle case.
40. INSTALL UNDERDRIVE CLUTCH ASSEMBLY
(a) Coat the bearing and bearing race with petrolatum,
and install them onto the underdrive clutch.
Standard bearing and bearing race diameter
(b) Install the underdrive clutch to the transaxle case.
NOTICE:
Do not damage the oil seal when installing the
underdrive clutch drum.
41. INSTALL PARKING LOCK PAWL
(a) Install the pawl pin and spring to the parking lock
pawl.
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Item Inside Outside
Bearing 37.73 mm (1.4854 in.) 58.0 mm (2.2835 in.)
Race 29.9 mm (1.1772 in.) 55.5 mm (2.185 in.)
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AX–234U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNIT
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50. INSTALL TRANSAXLE HOUSING
(a) Remove any packing material and be careful not to
spill oil on the contact surface of the transaxle case
or transaxle housing.
(b) Apply seal packing to the transaxle case.
Seal packing:
Toyota Genuine Seal Packing 1281,
Three Bond 1281 or Equivalent
(c) Apply adhesive or equivalent to bolts A and D.
Adhesive:
Toyota Genuine Adhesive 1344,
Three Bond 1344 or Equivalent
(d) Install the transaxle housing and 16 bolts to the
transaxle case.
Torque: 22 N*m (224 kgf*cm, 16 ft.*lbf) for bolt A
29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt B
29 N*m (295 kgf*cm, 21 ft.*lbf) for bolt C
22 N*m (226 kgf*cm, 16 ft.*lbf) for bolt D
HINT:
Each bolt length is indicated below.
Bolt length:
50 mm (1.97 in.) for bolt A
50 mm (1.97 in.) for bolt B
42 mm (1.65 in.) for bolt C
72 mm (2.84 in.) for bolt D
NOTICE:
Tighten the bolts within 10 minutes of adhesive
application.
51. INSPECT INPUT SHAFT END PLAY
(a) Using a dial indicator, measure the input shaft end
play.
Standard end play:
0.262 to 1.249 mm (0.0100 to 0.0494 in.)
52. FIX AUTOMATIC TRANSAXLE ASSEMBLY
(a) Fix the transaxle.
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U151E AUTOMATIC TRANSAXLE – AUTOMATIC TRANSAXLE UNITAX–235
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53. INSTALL MANUAL VALVE LEVER SHAFT OIL SEAL
(a) Coat a new oil seal with MP grease.
(b) Install the oil seal to the transaxle case.
SST 09950-60010 (09951-00230), 09950-70010
(09951-07100)
Standard depth:
0 +-0.5 mm (0 +-0.197 in. )
54. INSTALL PARKING LOCK ROD SUB-ASSEMBLY
(a) Install the parking lock rod to the manual valve lever.
55. INSTALL MANUAL VALVE LEVER SUB-ASSEMBLY
(a) Install a new spacer and manual valve lever shaft to
the transaxle case.
NOTICE:
Do not damage the oil seal when installing the
shaft to the transaxle case.
(b) Using a pin punch and hammer, drive in a new pin.
(c) Turn the spacer and the lever shaft to align the small
hole for locating the staking position in the spacer
with the staking position mark on the lever shaft.
(d) Using a pin punch, stake the spacer through the
small hole.
(e) Check that the spacer does not turn.
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AX–248U151E AUTOMATIC TRANSAXLE – OIL PUMP
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REASSEMBLY
1. INSTALL FRONT OIL PUMP OIL SEAL
(a) Using SST and a hammer, tap in a new oil seal to
the oil pump body.
SST 09350-32014 (09351-32140)
HINT:
The seal end should be flat with the outer edge of
the oil pump.
(b) Coat the lip of the oil seal with MP grease.
2. INSTALL FRONT OIL PUMP BODY O-RING
(a) Coat a new O-ring with ATF, and install it to the oil
pump body.
NOTICE:
• Make sure that the O-ring is not twisted or
pinched.
• Apply enough ATF to the O-ring before
installation.
3. INSTALL FRONT OIL PUMP DRIVEN GEAR
(a) Coat the front oil pump driven gear with ATF, and
install it to the oil pump body with the marked side
facing upward.
4. INSTALL FRONT OIL PUMP DRIVE GEAR
(a) Coat the front oil pump drive gear with ATF, and
install it to the oil pump body with the marked side
facing upward.
5. INSTALL STATOR SHAFT ASSEMBLY
(a) Set the stator shaft and align it with each bolt hole.
(b) Using a T30 "torx" socket, install the 11 bolts.
Torque: 9.8 N*m (100 kgf*cm, 87 in.*lbf)
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U151E AUTOMATIC TRANSAXLE – OIL PUMPAX–249
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6. INSTALL CLUTCH DRUM OIL SEAL RING
(a) Coat 2 new oil seal rings with ATF.
(b) Install 2 new clutch drum oil seal rings.
NOTICE:
Do not expand the ring ends excessively.
7. INSPECT OIL PUMP ASSEMBLY (See page AX-246)
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U151E AUTOMATIC TRANSAXLE – FORWARD CLUTCHAX–255
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(d) Remove the forward clutch return spring from the
input shaft.
4. REMOVE FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Place the forward clutch drum onto the oil pump.
(b) Holding the forward clutch piston by hand, apply
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi) to the
oil pump to remove the forward clutch piston.
HINT:
When the piston cannot be removed because it is
slanted, blow air again with the protruding side
pushed, or remove the piston using needle nose
pliers with vinyl tape on the tip.
5. REMOVE INPUT SHAFT OIL SEAL RING
(a) Remove the input shaft oil seal ring from the input
shaft.
INSPECTION
1. INSPECT PACK CLEARANCE OF FORWARD
CLUTCH
(a) Install the forward clutch on the oil pump.
NOTICE:
Be careful not to damage the oil seal ring of the
oil pump.
(b) Using a dial indicator, measure the forward clutch
pack clearance while applying and releasing
compressed air (392 kPa, 4.0 kgf/cm
2, 57 psi).
Standard pack clearance:
1.00 to 1.25 mm (0.0394 to 0.4921 in.)
If the clearance is not as specified, inspect the
discs, plates and flange.
HINT:
If the opening is large, cover it with a piece of cloth
to prevent the compressed air from being released.
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AX–256U151E AUTOMATIC TRANSAXLE – FORWARD CLUTCH
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2. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Check if the sliding surface of the disc, plate and
flange are worn or burnt.
If necessary, replace them.
NOTICE:
• If the lining of the disc comes off or is
discolored, or if a part of the groove is worn,
replace all the discs.
• Before installing new discs, immerse them in
ATF for at least 15 minutes.
3. INSPECT FORWARD CLUTCH RETURN SPRING
SUB-ASSEMBLY
(a) Using a vernier caliper, measure the free length of
the spring together with the spring seat.
Standard free length:
26.74 mm (1.0528 in.)
4. INSPECT FORWARD MULTIPLE DISC CLUTCH DISC
(a) Check if the disc lightly rotates when rotating the
forward clutch after inserting the multiple disc clutch
into it.
NOTICE:
Do not place the forward clutch in a vise.
REASSEMBLY
1. INSTALL INPUT SHAFT OIL SEAL RING
(a) Compress a new input shaft oil seal ring from both
sides to reduce dimension A.
Dimension A:
5.0 mm (0.197 in.)
(b) Coat the oil seal ring with ATF and install it to the
forward clutch drum.
NOTICE:
Do not expand the end gap of the oil seal ring
too much. Fix the hooks firmly.
2. INSTALL FORWARD CLUTCH PISTON SUB-
ASSEMBLY
(a) Coat the forward clutch piston with ATF, and install it
to the forward clutch drum.
NOTICE:
Be careful not to damage the lip of the forward
clutch piston.
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AX–170U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEAL
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REPLACEMENT
1. REPLACE TRANSAXLE HOUSING OIL SEAL LH
(a) Drain the automatic transaxle fluid.
(1) Remove the drain plug and gasket, and drain
the ATF.
(2) Install a new gasket and drain plug.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)
(b) Remove the front drive shaft LH (see page DS-41).
(c) Remove the transaxle housing oil seal LH.
(1) Using SST, tap out the oil seal.
SST 09308-00010
(d) Install a new transaxle housing oil seal LH.
(1) Coat the lip of a new oil seal with MP grease.
(2) Using SST and a hammer, tap in the oil seal.
SST 09223-15020, 09950-70010 (09951-
07200)
Standard depth:
0 +-0.5 mm (0 +-0.020 in.)
(e) Install the front drive shaft LH (see page DS-66).
(f) Add automatic transaxle fluid.
Fluid type:
Toyota Genuine ATF WS
(g) Inspect the transaxle fluid level (see page AX-126).
2. REPLACE TRANSAXLE HOUSING OIL SEAL RH
(a) Remove the engine assembly with transaxle (see
page EM-21).
(b) Drain the automatic transaxle fluid.
(1) Remove the drain plug and gasket, and drain
the ATF.
(2) Install a new gasket and the drain plug.
Torque: 47 N*m (479 kgf*cm, 35 ft.*lbf)
(c) Remove the 3 bolts and drive shaft bearing bracket.
(d) Remove the 3 bolts and rear engine mounting
bracket.
(e) Remove the transfer assembly (see page TF-59).
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U151F AUTOMATIC TRANSAXLE – DIFFERENTIAL OIL SEALAX–171
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(f) Remove the transaxle housing oil seal RH.
(1) Using a screwdriver with vinyl tape wound
around its tip, remove the oil seal.
NOTICE:
Be careful not to damage the housing.
(g) Install a new transaxle housing oil seal RH.
(1) Coat the lip of a new oil seal with MP grease.
(2) Using SST and a hammer, tap in the oil seal.
SST 09649-17010, 09950-70010 (09951-
07200)
Standard depth:
6.0 +-0.5 mm (0.236 +-0.020 in.)
(h) Install the transfer assembly (see page TF-75).
(i) Install the rear engine mounting bracket with the 3
bolts.
Torque: 64 N*m (652 kgf*cm, 47 ft.*lbf)
(j) Install the drive shaft bearing bracket with the 3
bolts.
Torque: 64 N*m (653 kgf*cm, 47 ft.*lbf)
(k) Install the engine with transaxle (see page EM-31).
(l) Add automatic transaxle fluid.
Fluid type:
Toyota Genuine ATF WS
(m) Inspect the fluid level (see page AX-126).
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